Hybrid fascia mounted exhaust tip assembly

ABSTRACT

An exhaust module made of a thermoplastic material which is connected to a fascia or bumper of a vehicle. In one embodiment, the hybrid fascia mounted exhaust tip assembly includes a bracket. The bracket has a large diameter portion which surrounds, but is not in contact with, an exhaust pipe. The exhaust pipe is free to move around as a result of the vehicle traveling over bumps in the road and around turns. The bracket also has a small diameter portion which is connected to the large diameter portion. A ring tip has a portion that slides onto a bezel portion of the small diameter portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/351,776, filed Jan. 17, 2012, which claims the benefit of U.S.Provisional Application No. 61/574,251, filed Jul. 29, 2011 and U.S.Provisional Application No. 61/574,330, filed Aug. 1, 2011.

FIELD OF THE INVENTION

The present invention relates to hybrid fascia mounted exhaust modulemade primarily of thermoplastic material resistant to corrosion, whichrequires minimal secondary operations during assembly.

BACKGROUND OF THE INVENTION

Exhaust systems are used for just about every type of vehicle currentlyin production around the world. It is commonplace for vehicle owners toadd accessories to the vehicle to change the appearance of the vehicle.Once particular type of accessory is a decorative exhaust tip typicallymade of steel or another type of metal which is chrome plated to providefor an aesthetically pleasing appearance.

One type of design uses a slip-on type steel exhaust tip that isconnected directly to the end of the exhaust pipe. This design issubject to corrosion and requires additional welding during assemblyoperations.

FIGS. 1-2 depict a prior art design that has a metal exhaust module 100that attaches to the rear bumper fascia 102 of the vehicle. The exhaustmodule 100 has metal body 104 and welded mounting flanges 106. Thewelded flanges 106 are used to connect the metal body 104 a largerspacer bracket 108 that connects to the rear fascia 102. The connectionof the welded flanges 106, spacer 108 and rear fascia 102 is made withseveral bolts 110 and nuts 112. An outer surface 114 of the metal body104 is often chrome polished or painted and can be seen when a personlooks at the rear bumper fascia 102 of the vehicle. The exhaust module100 is not connected to the exhaust pipe but has an inlet portion 103that is positioned in close relation to the end of the exhaust gastailpipe for receiving and passing exhaust gas through the exhaustmodule. Exhaust modules of this type often are formed of several weldedsteel parts and brackets that come into direct contact with the exhaustgas from the exhaust pipe being formed of steel or some other types ofmetal.

The above described designs result in undesirable gap between the chrometip of the exhaust tip or exhaust module and the rear bumper fascia ofthe vehicle because the design must account for thermal expansion of themetal portions exposed to the hot gasses from the exhaust pipe. Theexhaust modules designs that mount to the rear fascia also add aconsiderable amount of weight causing undue stress on the rear fascia,which is often made of plastic. Also both the metal slip on exhaust tipand exhaust module designs described above are costly to produce becausethey are primarily made of metal. It is therefore desirable to design anexhaust module that is light weight, low cost, and aestheticallypleasing by having a tight fit or minimal gap to the rear fascia of thevehicle. It is also desirable to produce an exhaust gas module that hasa minimal number of components for ease of assembly, which would alsoresult in cost savings.

SUMMARY OF THE INVENTION

The present invention is an exhaust module made of a thermoplasticmaterial which is connected to a fascia or bumper of a vehicle. In oneembodiment, the hybrid fascia mounted exhaust tip assembly includes abracket. The bracket has a large diameter portion which surrounds, butis not in contact with, an exhaust pipe. The exhaust pipe is free tomove around as a result of the vehicle traveling over bumps in the roadand around turns. The bracket also has a small diameter portion which isconnected to the large diameter portion. A ring tip has a portion thatslides onto a bezel portion of the small diameter portion. Theconnection between the ring tip and the small diameter portion providesfor a reduced clearance between the ring tip and the fascia, helping toprovide for an aesthetically pleasing appearance. In one embodiment, thering tip is chrome plated. In other embodiments, the ring tip may bemade of bright stainless steel, and stamped into the correct shape.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a prior art exhaust gas moduleand fascia;

FIG. 2 is a side plan view of a mounted prior art exhaust gas module toa rear fascia of a vehicle;

FIG. 2A is an exploded perspective view of an exhaust gas module inaccordance with one embodiment of the present invention;

FIG. 2B is a perspective view of an assembled exhaust gas module inaccordance with one embodiment of the present invention;

FIG. 3A is a schematic side view diagram of a prior art exhaust tipconnected to an exhaust pipe and positioned relative to a portion of apartially broken away portion of the rear fascia;

FIG. 3B is a side schematic view of an exhaust module relative to therear fascia and exhaust pipe in accordance to one embodiment of thepresent invention;

FIG. 4A is a perspective view of an alternate embodiment of a ring tipassembly in accordance with one embodiment of the present invention;

FIG. 4B is an exploded perspective view of an alternate embodiment ofthe bracket assembly and ring tip assembly of the exhaust gas module inaccordance with the present invention;

FIG. 4C is a perspective view of the assembled exhaust gas module ofFIG. 4B;

FIG. 5 is a cross-sectional plan view of the exhaust gas moduleassembled to the bracket taken along section line 5 in FIG. 2B;

FIG. 6 is an exploded perspective view of an alternate embodiment of theexhaust module assembly wherein the bracket is integrated into the rearfascia;

FIG. 7A is a cross-sectional side schematic view of a mold machine foran alternate embodiment of the present invention where the ring tip isinsert molded to the bracket;

FIG. 7B is a cross-sectional side schematic view of a mold machine foran alternate embodiment of the present invention where the ring tip isinsert molded to the bracket; and

FIG. 7C is a cross-sectional side view of an alternate embodiment of theexhaust module wherein the ring tip has been insert molded onto thebracket.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to the FIGS. 2A, 2B, 4A, 4B, 4C, 5, 6 and 7C, which are thefigures of the embodiments of the present invention generally, anexhaust module according to the present invention is shown generally at10. The module 10 includes a bracket, shown generally at 12, and a ringtip, shown generally at 14. The bracket 12 has a plurality of mountingflanges 16, which are used for connecting the bracket 12 to the fasciaor bumper of a vehicle (not shown).

The bracket 12 includes a large diameter portion 18 and a small diameterportion 20. The large diameter portion 18 surrounds the end portion ofan exhaust pipe 22, which is connected to a muffler, or other exhaustsystem component. The large diameter portion 18 is about four inches indiameter, and the exhaust pipe 22 is about two inches in diameter, whichcreates about a one-inch clearance between the exhaust pipe 22 and thelarge diameter portion 18 of the bracket 12. This clearance limits theexposure of the bracket 12 to the temperatures of the exhaust pipe 22,and allows for the exhaust pipe 22 to have some movement, or “play,” asthe vehicle travels over bumps, around curves, and the like. While adiameter of four inches for the large diameter portion and a diameter oftwo inches for the exhaust pipe is disclosed, it is within the scope ofthis invention for different diameters to be used depending upon thesize of the diametrical size of the exhaust pipe.

The bracket 12 in one embodiment of the invention is formed entirely ofplastic or polymer such as glass filled nylon, ABS or other polymermaterials such as thermoplastic olefins. Forming the bracket 12 out ofentirely polymer material is a significant advantage over the prior artwhich is typically formed of some type of metal, such as steel.Therefore, it is within the scope of this invention for the bracket 12and to not be formed of metal. It is also within the scope of thisinvention for the bracket 12 including the large diameter portion 18,small diameter potion 20 to not be formed of metal. It is further withinthe scope of this invention for the bracket 12, including the largediameter portion 18, small diameter portion 20 and mounting flanges 16to not be formed of metal. It is also within the scope of this inventionfor the bracket 12, including the large diameter portion 18, smalldiameter portion 20, mounting flanges 16 and ring tip 14 to not beformed of metal.

The connection between the ring tip 14 and bracket 12 can vary dependingon the particular embodiment of the invention. Referring to FIGS. 2A, 2Band 5 the ring tip 14 is connected to the bracket 12 by snap fit tabs.The ring tip 14 has resilient tabs 34 having apertures 36 that connectwith protrusions 38 formed on the bracket 12. In another embodiment ofthe invention shown in FIGS. 4A and 4B the ring tip 14 is slid over thesmall diameter portion 20 until the mounting features 26 of the smalldiameter portion 20 becomes interlocked with the mounting features 28formed integrally with a sleeve 30 of the ring tip 14. In thisparticular embodiment the mounting features 26, 28 are a “toy tab” ortongue in groove feature. In other embodiments, the ring tip 14 andbracket 12 are connected through other processes, such as adhesion,vibration welding, or the like.

In the embodiments of the invention described herein the bracket 12 hasa small diameter portion 20. The small diameter portion 20 is connectedto the large diameter portion 18 through a tapered portion or bezelportion 24. The sleeve 30 of the ring tip 14 terminates at a groove 32portion of the ring tip that receives at least part of the smalldiameter portion 20 when the module 10 is assembled together. Whenassembled the bezel portion of the small diameter portion 20 restsagainst and supports the ring tip 14. This allows the ring tip 14 to bemade thinner, which cuts cost and weight. The ring tip 14 in oneembodiment is formed of thin gauge stainless steel that is less thanfifty thousandths of an inch thick. In another embodiment of theinvention the ring tip 14 is formed of thin gauge stainless steel thatis between twenty thousandths to forty thousandths of an inch thick. Inanother embodiment of the invention the ring tip 14 is formed of thingauge stainless steel that is between twenty thousandths and thirtythousandths of an inch thick. The thickness of the ring tip 14 can varydepending upon the environmental factors, including exhaust gastemperatures exposure for a particular application. It is also possiblefor the ring tip 14 to be formed of polymeric material and would includea chrome plated plastic that is accomplished using a PolychlorinatedBiphenyls PCBs resin or ABS resin with subsequent chrome plating of theresin material.

An alternate method of assembling the ring tip 14 to the bracket 12 isshown in FIGS. 7A-7C wherein insert molding is used to connect the ringtip 14 to the bracket 12. This process involves pre-forming the ring tip14, which has flow grooves 15 formed at opposite edges of the ring tip14. The ring tip 14 is placed into a mold cavity of a first platen 48 ofa molding machine 46. A second platen 50 is closed on to the firstplaten 48 and molten polymer 52 is flowed into the molding machine 46 toform the bracket 12. The ring tip 14 becomes connected to the bracket 12by molten polymer 52 material flowing into the flow grooves 15 of thering tip 14 prior to solidifying and forming the completed bracket 12.

Once the ring tip 14 is connected to the bracket 12 according to eitherthe snap fit, toy tab, or insert molded methods of assembly describedabove, the ring tip 14 is brushed and polished to achieve anaesthetically acceptable part. Performing the brush and polish step onceassembly is completed allows for the removal of any mold releasematerial that can be present, particularly if the insert molding methodof assembly is used. The brush polishing step also removes scratches orflash material that can be present on the ring tip 14.

FIG. 6 shows another alternate embodiment of the invention wherein anexhaust module 300 is integrated into a fascia 302. In this particularembodiment of the invention, the bracket 12 shown in the otherembodiments is not present since the exhaust module 300 is molded intothe rear fascia during the process of forming the rear fascia. Once therear fascia 302 is conformed, a large diameter portion 18 and smalldiameter portion 20 is present and is capable of receiving the ring tip14. The ring tip 14 can connect to the small diameter portion 20 in thesame manner as described in all the embodiments above. This particularembodiment of the invention further eliminates components by no longerrequiring a bracket 12 and fasteners for connecting to the rear fascia.Additionally, prior to assembly of the ring tip 14, the fascia 302 canbe painted or completed without any special or additional steps sincethe ring tip 14 will be connected to the small diameter portion 20 in asubsequent step. Therefore, there is no concern about painting ortreating the exhaust module 300 during the formation of the fascia 302.

Referring now to FIGS. 3A and 3B, the advantages of the presentinvention are over prior art as shown. FIG. 3A is a schematic side viewof a prior art steel exhaust tip assembly 200. A steel exhaust tip 202is connected to the end of an exhaust tail pipe 204, usually by welding,fasteners or some other attachment mechanism. The steel exhaust tip 202is positioned below a rear fascia 208 at a distance that provides asuitable gap 206 between the rear fascia 208 and the steel exhaust tip202. The gap 206 distances can vary but is usually approximately 28 mmor enough distance to account for thermal expansion of the exhaust tip202 and movement of the assembly 200 as the vehicle moves.

FIG. 3B shows the exhaust module 10 schematically assembled to a rearfascia 40 in accordance with the present invention. A gap 44 is shownbetween the exhaust module 10 and rear fascia 40. The gap 44 is lessthan or equal to 5 mm. Thus, the present invention is an improvementover the prior art because a more aesthetically pleasing appearance canbe achieved due to the tighter fit and reduced gap 44 between theexhaust module 10 and rear fascia 40.

One reason for the present invention's improvement over prior designs isthat the prior designs use a large percentage of metal parts, whichrequires the designs to account for thermal expansion of the exhaust tipor steel exhaust module. The exhaust module 10 of the present inventionis formed entirely of polymer material and in one embodiment implementsa thin gauge steel ring tip 14. A smaller gap can be achieved since thepolymer material of the exhaust module 10 will not be subject to thesame level of thermal expansion that the prior modules are exposed to.Thus, forming the exhaust module 10 of polymer material represents animprovement over existing exhaust modules and exhaust tip designs.

The bracket 12 is a glass-filled, nylon part, or is made from anothertype of thermoplastic material. The ring tip 14 is made from apolycarbonate (PC), acrylonitrile butadiene styrene (ABS), or other typeof thermoplastic material which is injection molded. The ring tip 14 isalso chrome plated, to provide an aesthetically pleasing appearance.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the essence of the inventionare intended to be within the scope of the invention. Such variationsare not to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. An exhaust module assembly for a vehiclecomprising; a bracket formed entirely of polymer; a large diameterportion of said bracket, said large diameter portion surrounding, butnot in contact with an exhaust pipe, thereby creating a clearancebetween the exhaust pipe and the large diameter portion; a smalldiameter portion of said bracket connected to said large diameterportion; and a ring tip connected to said small diameter portion.
 2. Theexhaust module of claim 1, further comprising a bezel portion of saidsmall diameter portion wherein a sleeve of said ring tip slides ontosaid bezel portion and said bezel portion supports said ring tip.
 3. Theexhaust module of claim 1, wherein said ring tip is made from oneselected from the group consisting of polycarbonate (PC), acrylonitrilebutadiene styrene (ABS), and combinations thereof and said ring top ischrome plated.
 4. The exhaust module of claim 1, wherein said ring tipis made from a thin-gauge bright stainless steel having a thickness lessthan fifty thousandths of an inch.
 5. The exhaust module of claim 1,wherein said bracket is made from a polymer, one selected from the groupcomprising a glass-filled nylon material, thermoplastic olefin,acrylonitrile butadiene styrene and combinations thereof.
 6. The exhaustmodule of claim 1, wherein said ring tip and said bracket are connectedthrough one process selected from the group consisting of a mechanicalconnection, adhesion, vibration welding, and combinations thereof. 7.The exhaust module of claim 1 wherein said bracket is not farmed ofmetal.
 8. The exhaust module of claim 1 wherein said ring assembly isnot made of metal.
 9. The exhaust module of claim 1 further comprising:a rear fascia; one or more mounting flanges formed on said bracket forconnecting said bracket to said rear fascia.
 10. The exhaust moduleassembly of claim 1 further comprising: one or more mounting features onsaid ring tip, and one or more mounting features on said small diameterportion for engaging said one or more mounting features on said ring tipand connecting said ring tip to said small diameter portion of saidbracket.
 11. The exhaust module assembly of claim 10 wherein said one ormore mounting features on said ring tip include a resilient tab with anaperture and said one or more mounting features on said small diameterassembly are protrusions formed on the surface of said small diameterportion for engaging an aperture of said resilient tabs.
 12. The exhaustmodule assembly of claim 11 wherein said one or more mounting featureson said ring tip and said one or more mounting features on said smalldiameter portion are one selected from the group comprising lockingtabs, toy-tabs and tongue-in-groove locking mechanisms.
 13. The exhaustmodule assembly of claim 1 wherein said bracket is integrated with arear fascia and said ring tip is connected to said bracket of said rearfascia after said rear fascia is created.
 14. The exhaust moduleassembly of claim 10 wherein a gap defined by the distance between saidring tip and said rear fascia is less than 5 mm.
 15. An exhaust moduleassembly for a vehicle comprising: a rear fascia; a bracket having oneor more mounting flanges formed on said bracket for connecting to saidrear fascia; a large diameter portion of said bracket surrounding, butnot in contact with an exhaust pipe, thereby creating a clearancebetween the exhaust pipe and large diameter portion; a small diameterportion of said bracket connected to said large diameter portion, saidsmall diameter having a bezel portion; one or more mounting featuresformed on said small diameter portion; a ring tip connected to saidsmall diameter portion, wherein said ring tip has a sleeve configured toslide onto and be supported by said bezel portion; and one or moremounting features on said ring tip for connecting said ring tip to saidone or more mounting features of said small diameter portion.
 16. Theexhaust module of claim 15, wherein said ring tip is made from oneselected from the group consisting of polycarbonate (PC), acrylonitrilebutadiene styrene (ABS), and combinations thereof and said ring tip ischrome plated.
 17. The exhaust module of claim 16, wherein said ring tipis made from a thin-gauge bright stainless steel having a thickness lessthan fifty thousandths of an inch.
 18. The exhaust module of claim 15wherein said bracket is made from a polymer, one selected from the groupcomprising a glass-filled nylon material, thermoplastic olefin;acrylonitrile butadiene styrene and combinations thereof.
 19. Theexhaust module of claim 15 wherein a gap defined by a distance betweensaid ring tip and said rear fascia is less than 5 mm.
 20. A method ofinsert molding an exhaust module assembly for a vehicle comprising thesteps of: providing a mold machine having a first platen and a secondplaten for receiving molten polymer; providing a ring tip having one ormore flow grooves formed on said ring tip; placing said ring tip intosaid first platen of said mold machine; moving said second platen intooperative engagement with said first platen and flowing molten polymerinto said mold machine, wherein said molten polymer flows into said oneor more flow grooves of said ring tip; forming said molten polymer intoa bracket formed entirely of polymer, said bracket including a largediameter portion said bracket for surrounding, but not in contact withan exhaust pipe when said bracket is connected to the vehicle, therebycreating a clearance between the exhaust pipe at the large diameterportion and a small diameter portion of said bracket connected to saidlarge diameter portion ring tip is connected to the small diameterportion when said molten polymer flows into said one or more flowgrooves; and moving said second platen away from said first platen andremoving said bracket and said ring tip which now form said exhaustmodule assembly.
 21. A method of claim 20 further comprising the step ofpolishing said ring tip.